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US20190090350A1 - Multilayered Flexible Electronics Platform - Google Patents

Multilayered Flexible Electronics Platform Download PDF

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Publication number
US20190090350A1
US20190090350A1 US16/133,691 US201816133691A US2019090350A1 US 20190090350 A1 US20190090350 A1 US 20190090350A1 US 201816133691 A US201816133691 A US 201816133691A US 2019090350 A1 US2019090350 A1 US 2019090350A1
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Prior art keywords
flexible
layer
water
multilayered
power
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Granted
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US16/133,691
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US10842022B2 (en
Inventor
Rajan Kumar
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Boudreaux Hale
Carnahan Kristin
Ocella Inc
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Individual
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Priority to US16/133,691 priority Critical patent/US10842022B2/en
Publication of US20190090350A1 publication Critical patent/US20190090350A1/en
Assigned to OCELLA INC reassignment OCELLA INC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KUMAR, RAJAN
Application granted granted Critical
Publication of US10842022B2 publication Critical patent/US10842022B2/en
Assigned to BOUDREAUX, HALE, Carnahan, Kristin reassignment BOUDREAUX, HALE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CB Stability LLC
Assigned to OCELLA INC reassignment OCELLA INC CORRECTIVE ASSIGNMENT TO CORRECT THE THE ASSIGNMENT FILED AFTER THE ASSIGNMENT WITH REEL/FRAME 061338/0191 IS INVALID, AS THE ASSIGNOR WAS NOT THE ASSIGNEE AT THE TIME. THE PREVIOUS ASSIGNMENT REEL/FRAME 053142/0991 SHOULD BE REINSTATED, AND ASSIGNMENT WITH REEL/FRAME 061338/0191 SHOULD BE CANCELLED PREVIOUSLY RECORDED ON REEL 53142 FRAME 991. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Assignors: KUMAR, RAJAN
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/18—Printed circuits structurally associated with non-printed electric components
    • H05K1/189—Printed circuits structurally associated with non-printed electric components characterised by the use of a flexible or folded printed circuit
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2/0275—
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/116—Primary casings; Jackets or wrappings characterised by the material
    • H01M50/117—Inorganic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/116—Primary casings; Jackets or wrappings characterised by the material
    • H01M50/121—Organic material
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/10—Circuit arrangements or systems for wireless supply or distribution of electric power using inductive coupling
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0042—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries characterised by the mechanical construction
    • H02J7/025—
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/0274—Optical details, e.g. printed circuits comprising integral optical means
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/0277—Bendability or stretchability details
    • H05K1/028—Bending or folding regions of flexible printed circuits
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/03—Use of materials for the substrate
    • H05K1/0393—Flexible materials
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/11—Printed elements for providing electric connections to or between printed circuits
    • H05K1/118—Printed elements for providing electric connections to or between printed circuits specially for flexible printed circuits, e.g. using folded portions
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/46—Manufacturing multilayer circuits
    • H05K3/4644—Manufacturing multilayer circuits by building the multilayer layer by layer, i.e. build-up multilayer circuits
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/46—Manufacturing multilayer circuits
    • H05K3/4688—Composite multilayer circuits, i.e. comprising insulating layers having different properties
    • H05K3/4691—Rigid-flexible multilayer circuits comprising rigid and flexible layers, e.g. having in the bending regions only flexible layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/72—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/202—Conductive
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F1/00—Details not covered by groups G06F3/00 - G06F13/00 and G06F21/00
    • G06F1/16—Constructional details or arrangements
    • G06F1/1613—Constructional details or arrangements for portable computers
    • G06F1/163—Wearable computers, e.g. on a belt
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M6/00—Primary cells; Manufacture thereof
    • H01M6/40—Printed batteries, e.g. thin film batteries
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/34—Parallel operation in networks using both storage and other dc sources, e.g. providing buffering
    • H02J7/35—Parallel operation in networks using both storage and other dc sources, e.g. providing buffering with light sensitive cells
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/16—Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/05—Flexible printed circuits [FPCs]
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/09—Shape and layout
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10007—Types of components
    • H05K2201/10098—Components for radio transmission, e.g. radio frequency identification [RFID] tag, printed or non-printed antennas
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/22—Secondary treatment of printed circuits
    • H05K3/28—Applying non-metallic protective coatings
    • H05K3/284—Applying non-metallic protective coatings for encapsulating mounted components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present invention relates generally to a thin-film electronic device. More specifically, the present invention relates to a flexible device that uses layers of thin-film electronics to harvest energy from the environment, surroundings, or body and/or to form a device capable of powering any number of integrated electrical modules.
  • the present invention addresses these challenges by using thin-film electronics to create flexible electronic systems.
  • the present invention leverages the capabilities of circuits, electronics, and batteries to create as a flexible sheet of material that functions as a self-sufficient electronic system.
  • the present invention makes use of a battery layer to store the electrical charge required to power a flexible layer of electronic devices.
  • This invention may also make use of an energy harvesting layer to generate power.
  • the present invention encases all of the flexible electronic components in a water-impermeable casing or membrane that protects the components from hazards in the external environment. This construction enables the present invention to be integrated into clothing and can be used to cover various other surfaces.
  • FIG. 1 is a schematic diagram of the present invention.
  • FIG. 2 is a schematic diagram of the electronic connections within the present invention.
  • FIG. 3 is a schematic diagram of the electrical connections within the present invention.
  • FIG. 4 is a schematic diagram of an embodiment of the present invention, wherein the embodiment is a multi-sectioned foldable sheet.
  • the present invention is a multilayer flexible electronics platform that integrates thin-film electronic devices into a flexible membrane.
  • the present invention can be used in a wide variety of applications, which includes, but not limited to, textiles, material coatings, and wearable devices.
  • the present invention comprises at least one functional unit 1 , each of which comprises a flexible water-impermeable envelop 2 , a flexible power-source layer 5 , a flexible printed circuit board (PCB) layer 6 , and a flexible accessory-interfacing layer 7 .
  • the flexible water-impermeable envelop 2 is used to seal the other electronic components of the present invention in a protective enclosure.
  • the flexible water-impermeable envelop 2 is preferably made of rubber, silicone, polyurethane, or some other similar material.
  • the flexible power-source layer 5 is used to store energy and to readily power the other electronic components of the present invention.
  • the flexible power-source layer 5 is preferably a flexible, elastic, flat battery that is a printed thin-film device.
  • the flexible power-source layer 5 can alternatively be a supercapacitor or a hybrid battery/supercapacitor.
  • the flexible PCB layer 6 regulates the power distribution from the flexible power-source layer 5 and manages commands and other pieces of data that are exchanged between the flexible PCB layer 6 and the flexible accessory-interfacing layer 7 .
  • the flexible accessory-interfacing layer 7 allows for other modular electronic devices to be electrically and electronically attached to the present invention. These modular electronic devices include, but is not limited to, sensors, light emitting diodes (LEDs), solar panels, display devices, speakers, and user-interface devices.
  • the general configuration of the aforementioned components allows the present invention to efficiently and effectively maintain a flat shape so that the present invention can be easily integrated into a fabric or other flexible flat apparatus.
  • the flexible power-source layer 5 , the flexible PCB layer 6 , and the flexible accessory-interfacing layer 7 are stackably positioned amongst each other, which allows for the overall flat shape of the present invention. For example, if the present invention is integrated into a piece of clothing, then the overall flat shape prevents the present invention from becoming obtrusive and uncomfortable on the piece of clothing.
  • the flexible power-source layer 5 , the flexible PCB layer 6 , and the flexible accessory-interfacing layer 7 are positioned within the flexible water-impermeable envelop 2 so that these electronic components are protected from water and other kinds of damage. Again, for example, if the present invention is integrated into a piece of clothing, then the piece of clothing could be washed in water or worn in the rain without fear of damaging the present invention.
  • the flexible PCB layer 6 is electronically connected to the flexible power-source layer 5 and the flexible accessory-interfacing layer 7 in order to communicate digital signals between the flexible PCB layer 6 , the flexible power-source layer 5 , and the flexible accessory-interfacing layer 7 .
  • the flexible PCB layer 6 is also able to communicate digital signals with any modular electronic device that have been attached to the flexible accessory-interfacing layer 7 .
  • the flexible power-source layer 5 is electrically connected to the flexible PCB layer 6 and the flexible accessory-interfacing layer 7 , which allows the flexible power-source layer 5 to readily deliver power to the flexible PCB layer 6 , the flexible accessory-interfacing layer 7 , or any modular electronic devices that are attached to the flexible accessory-interfacing layer 7 .
  • each of the at least one functional unit 1 may further comprise an attachment mechanism 8 , which can be, but is not limited to, a combination of stitching and cloth, an adhesive patch, an adhesive film, a hook-and-loop fastener, a mechanical fastener, a wristband, or a headband.
  • the attachment mechanism 8 is externally mounted to the flexible water-impermeable envelop 2 so that the attachment mechanism 8 can be readily used to attach the flexible water-impermeable envelop 2 to the other larger object.
  • the at least one functional unit 1 may further comprise a base liner 3 and a sealant layer 4 .
  • the base liner 3 is used as a substrate to properly position the other components of the present invention.
  • the base liner 3 is preferably used to integrate the present invention into articles of clothing or to attach the present invention onto the surface of external devices.
  • the sealant layer 4 is used to enclose the other components of the present invention upon the base liner 3 .
  • the flexible power-source layer 5 , the flexible PCB layer 6 , and the flexible accessory-interfacing layer 7 are positioned in between the base liner 3 and the sealant layer 4 .
  • the base liner 3 and the sealant layer 4 are perimetrically connected to each other, which defines the internal space of the flexible water-impermeable envelop 2 that retains the flexible power-source layer 5 , the flexible PCB layer 6 , and the flexible accessory-interfacing layer 7 .
  • each of the at least one functional unit 1 may further comprise an energy-harvesting layer 9 , which is made of any material that can convert a changing physical property of the surrounding environment into an electrical current.
  • the energy-harvesting layer 9 is stackably positioned amongst the flexible power-source layer 5 , the flexible PCB layer 6 , and the flexible accessory-interfacing layer 7 and is positioned within the flexible water-impermeable envelop 2 . This arrangement allows for a change in a specific physical property of the present invention to potentially produce an electrical current with the energy-harvesting layer 9 . Consequently, the energy-harvesting layer 9 is electrically connected to the flexible power-source layer 5 so that the energy-harvesting layer 9 is able to recharge the flexible power-source layer 5 .
  • the energy-harvesting layer 9 can be applied in a variety of different embodiments.
  • One embodiment of the energy-harvesting layer 9 is a quantity of photoelectric material that is distributed throughout the flexible water-impermeable envelop 2 .
  • the flexible water-impermeable envelop 2 would need to be transparent so that light passing through the water-impermeable envelop could be converted into an electric current by the quantity of photoelectric material.
  • Another embodiment of the energy-harvesting layer 9 is a quantity of piezoelectric material (e.g. piezoelectric foam) that is distributed throughout the flexible water-impermeable envelop 2 .
  • the flexible water-impermeable envelop 2 would need to be crinkled, scrunched, or moved in some mechanically stressful manner in order to generate an electric current with the quantity of piezoelectric material.
  • Another embodiment of the energy-harvesting layer 9 is a quantity of pyroelectric material that is distributed throughout the flexible water-impermeable envelop 2 .
  • the flexible water-impermeable envelop 2 would need to be thermally conductive so that heat passing through the water-impermeable envelop could be converted into an electric current by the quantity of pyroelectric material.
  • Another embodiment of the energy-harvesting layer 9 is a quantity of triboelectric material that is distributed throughout the flexible water-impermeable envelop 2 .
  • the flexible water-impermeable envelop 2 would need to be moved in some frictional manner in order to generate an electric current with the quantity of triboelectric material.
  • each of the at least one functional unit 1 may further comprise a wireless charging module 10 , which preferably is an induction coil.
  • the wireless charging module 10 is positioned within the flexible water-impermeable envelop 2 in order to properly secure the wireless charging module 10 to the present invention.
  • the wireless charging module 10 is electrically connected to the flexible power-source layer 5 so that the wireless charging module 10 is able to recharge the flexible power-source layer 5 .
  • each of the at least one functional unit 1 may further comprise a wireless communication module 11 , which can be, but is not limited to, a module facilitating a personal area network (e.g. Bluetooth), a module facilitating near field communication (NFC), or a module facilitating radio-frequency identification (RFID).
  • the wireless communication module 11 is electronically integrated into the flexible PCB layer 6 so that the flexible PCB layer 6 is readily able to process incoming data from and/or outgoing data to the wireless communication module 11 .
  • the present invention may also be configured as a multi-sectioned foldable sheet.
  • the at least one functional unit 1 needs to be a plurality of functional units 1
  • the present invention needs to further comprise a plurality of conductive strips 12 .
  • the plurality of functional units 1 is arranged into a grid configuration so that the flexible water-impermeable envelop 2 of each of the plurality of functional units 1 can be foldably connected amongst each other. This allows the present invention to be configured into a multi-sectioned foldable sheet.
  • the flexible power-source layer 5 of each of the plurality of functional units 1 is electrically connected amongst each other by a corresponding strip from the plurality of conductive strips 12 , which allows each of the plurality of functional units 1 to share power amongst each other.
  • One use of the present invention is designed to be used to manufacture smart clothing that has the appearance of traditional textiles and the functionality of a piece of wearable technology.
  • the base liner 3 and the sealant layer 4 form a water-impermeable membrane around the flexible power-source layer 5 , the flexible PCB layer 6 , the energy-harvesting layer 9 , and/or the flexible accessory-interfacing layer 7 .
  • This configuration enables the present invention to be incorporated into a machine washable garment.
  • Another use of the present invention is as a thermally adaptive textile that is integrated into the base liner 3 and the sealant layer 4 .
  • the present invention would be able to change configuration in response to the user's body heat. This enables the present invention to expand when cooled and contract when heated. This functionality enables the present invention to moderate the user's body temperature.
  • the present invention can be implemented in a variety of other uses, which include, but is not limited to, the following.
  • Another use of the present invention is as a foldable battery-solar pack, which is an energy storage or harvesting device applied on a flat sheet can be folded into multiple layers and reducing significant area.
  • Another use of the present invention is as a weight-distributed flexible electronic device with a battery that can attach, slide, insert, zip, fasten, or snap onto a garment.
  • Another use of the present invention is as a flexible battery circuitry mounted to a wearable band.
  • Another use of the present invention is as a band integrated with a smart wearable device either connected physically or wirelessly.
  • Another use of the present invention is as a clothing container, drawer, or closest with wireless charging and a flexible battery apparatus.
  • Another use of the present invention is as a periphery garment of battery mount to textile that communicates to a smart phone or network.
  • Another use of the present invention is as an apparatus that monitors a person's mental health, a person's physical health, a person's wound, a person's sleeping habits.
  • Another use of the present invention is as a garment of drug delivery and monitoring.
  • Another use of the present invention is as a flexible circuit with battery and communications for impact measurement on a head mounted item (e.g. hat, helmet, headband, sweatband).
  • the present invention can also be designed to be dust resistant.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • Inorganic Chemistry (AREA)
  • Battery Mounting, Suspending (AREA)
  • Telephone Set Structure (AREA)

Abstract

A multilayer flexible electronics platform is an apparatus that allows modular thin-film electronics to be integrated into everyday flexible, flat objects such as pieces of clothing, material coatings, or wearable devices. The apparatus includes a flexible water-impermeable envelop, a flexible power-source layer, a flexible printed circuit board (PCB) layer, and a flexible accessory-interfacing layer. The flexible accessory-interfacing layer allows those modular thin-film electronics to be electronically and electrically attached to the apparatus. The flexible PCB layer allows the apparatus to control and manage those modular thin-film electronics. The flexible power-source layer is used to provide electrical power to those modular thin-film electronics. The flexible water-impermeable envelop protectively encloses those modular thin-film electronics and the aforementioned functional layers of the apparatus.

Description

  • The current application claims a priority to the U.S. Provisional Patent application Ser. No. 62/559,395 filed on Sep. 15, 2017. The current application is filed on Sep. 17, 2018 while Sep. 15, 2018 was on a weekend.
    • FIELD OF THE INVENTION
  • The present invention relates generally to a thin-film electronic device. More specifically, the present invention relates to a flexible device that uses layers of thin-film electronics to harvest energy from the environment, surroundings, or body and/or to form a device capable of powering any number of integrated electrical modules.
    • BACKGROUND OF THE INVENTION
  • The allure of wearable technology has been hanging over consumer electronics for decades. This technology promises to deliver inconspicuous devices that are integrated into commonplace items such as clothing and wearables. While integrating electronic components into rigid devices, such as watches or glasses, is a relatively straight forward process, integrating electronics into clothing has proved challenging for scientists and engineers. The challenges stem from two main obstacles. Namely, creating truly flexible electronic devices, and unobtrusively powering such devices.
  • The present invention, the multilayered flexible electronics platform, addresses these challenges by using thin-film electronics to create flexible electronic systems. The present invention leverages the capabilities of circuits, electronics, and batteries to create as a flexible sheet of material that functions as a self-sufficient electronic system. Specifically, the present invention makes use of a battery layer to store the electrical charge required to power a flexible layer of electronic devices. This invention may also make use of an energy harvesting layer to generate power. The present invention encases all of the flexible electronic components in a water-impermeable casing or membrane that protects the components from hazards in the external environment. This construction enables the present invention to be integrated into clothing and can be used to cover various other surfaces.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a schematic diagram of the present invention.
  • FIG. 2 is a schematic diagram of the electronic connections within the present invention.
  • FIG. 3 is a schematic diagram of the electrical connections within the present invention.
  • FIG. 4 is a schematic diagram of an embodiment of the present invention, wherein the embodiment is a multi-sectioned foldable sheet.
    •  DETAILED DESCRIPTION OF THE INVENTION
  • All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.
  • The present invention is a multilayer flexible electronics platform that integrates thin-film electronic devices into a flexible membrane. The present invention can be used in a wide variety of applications, which includes, but not limited to, textiles, material coatings, and wearable devices. As can be seen in FIG. 1, the present invention comprises at least one functional unit 1, each of which comprises a flexible water-impermeable envelop 2, a flexible power-source layer 5, a flexible printed circuit board (PCB) layer 6, and a flexible accessory-interfacing layer 7. The flexible water-impermeable envelop 2 is used to seal the other electronic components of the present invention in a protective enclosure. The flexible water-impermeable envelop 2 is preferably made of rubber, silicone, polyurethane, or some other similar material. The flexible power-source layer 5 is used to store energy and to readily power the other electronic components of the present invention. The flexible power-source layer 5 is preferably a flexible, elastic, flat battery that is a printed thin-film device. The flexible power-source layer 5 can alternatively be a supercapacitor or a hybrid battery/supercapacitor. The flexible PCB layer 6 regulates the power distribution from the flexible power-source layer 5 and manages commands and other pieces of data that are exchanged between the flexible PCB layer 6 and the flexible accessory-interfacing layer 7. The flexible accessory-interfacing layer 7 allows for other modular electronic devices to be electrically and electronically attached to the present invention. These modular electronic devices include, but is not limited to, sensors, light emitting diodes (LEDs), solar panels, display devices, speakers, and user-interface devices.
  • The general configuration of the aforementioned components allows the present invention to efficiently and effectively maintain a flat shape so that the present invention can be easily integrated into a fabric or other flexible flat apparatus. The flexible power-source layer 5, the flexible PCB layer 6, and the flexible accessory-interfacing layer 7 are stackably positioned amongst each other, which allows for the overall flat shape of the present invention. For example, if the present invention is integrated into a piece of clothing, then the overall flat shape prevents the present invention from becoming obtrusive and uncomfortable on the piece of clothing. Moreover, the flexible power-source layer 5, the flexible PCB layer 6, and the flexible accessory-interfacing layer 7 are positioned within the flexible water-impermeable envelop 2 so that these electronic components are protected from water and other kinds of damage. Again, for example, if the present invention is integrated into a piece of clothing, then the piece of clothing could be washed in water or worn in the rain without fear of damaging the present invention. In addition, the flexible PCB layer 6 is electronically connected to the flexible power-source layer 5 and the flexible accessory-interfacing layer 7 in order to communicate digital signals between the flexible PCB layer 6, the flexible power-source layer 5, and the flexible accessory-interfacing layer 7. Consequently, the flexible PCB layer 6 is also able to communicate digital signals with any modular electronic device that have been attached to the flexible accessory-interfacing layer 7. Furthermore, the flexible power-source layer 5 is electrically connected to the flexible PCB layer 6 and the flexible accessory-interfacing layer 7, which allows the flexible power-source layer 5 to readily deliver power to the flexible PCB layer 6, the flexible accessory-interfacing layer 7, or any modular electronic devices that are attached to the flexible accessory-interfacing layer 7.
  • The present invention is a retrofit device that is designed to be attached or adhered to another larger object. Thus, each of the at least one functional unit 1 may further comprise an attachment mechanism 8, which can be, but is not limited to, a combination of stitching and cloth, an adhesive patch, an adhesive film, a hook-and-loop fastener, a mechanical fastener, a wristband, or a headband. The attachment mechanism 8 is externally mounted to the flexible water-impermeable envelop 2 so that the attachment mechanism 8 can be readily used to attach the flexible water-impermeable envelop 2 to the other larger object.
  • In order for the present invention to maintain the overall flat shape, the at least one functional unit 1 may further comprise a base liner 3 and a sealant layer 4. The base liner 3 is used as a substrate to properly position the other components of the present invention. The base liner 3 is preferably used to integrate the present invention into articles of clothing or to attach the present invention onto the surface of external devices. The sealant layer 4 is used to enclose the other components of the present invention upon the base liner 3. Thus, the flexible power-source layer 5, the flexible PCB layer 6, and the flexible accessory-interfacing layer 7 are positioned in between the base liner 3 and the sealant layer 4. Moreover, the base liner 3 and the sealant layer 4 are perimetrically connected to each other, which defines the internal space of the flexible water-impermeable envelop 2 that retains the flexible power-source layer 5, the flexible PCB layer 6, and the flexible accessory-interfacing layer 7.
  • The present invention may also be configured to gather energy from its surrounding environment, which allows the present invention to be a self-sustaining system without an external power source. Thus, each of the at least one functional unit 1 may further comprise an energy-harvesting layer 9, which is made of any material that can convert a changing physical property of the surrounding environment into an electrical current. In addition, the energy-harvesting layer 9 is stackably positioned amongst the flexible power-source layer 5, the flexible PCB layer 6, and the flexible accessory-interfacing layer 7 and is positioned within the flexible water-impermeable envelop 2. This arrangement allows for a change in a specific physical property of the present invention to potentially produce an electrical current with the energy-harvesting layer 9. Consequently, the energy-harvesting layer 9 is electrically connected to the flexible power-source layer 5 so that the energy-harvesting layer 9 is able to recharge the flexible power-source layer 5.
  • The energy-harvesting layer 9 can be applied in a variety of different embodiments. One embodiment of the energy-harvesting layer 9 is a quantity of photoelectric material that is distributed throughout the flexible water-impermeable envelop 2. For this embodiment, the flexible water-impermeable envelop 2 would need to be transparent so that light passing through the water-impermeable envelop could be converted into an electric current by the quantity of photoelectric material. Another embodiment of the energy-harvesting layer 9 is a quantity of piezoelectric material (e.g. piezoelectric foam) that is distributed throughout the flexible water-impermeable envelop 2. For this embodiment, the flexible water-impermeable envelop 2 would need to be crinkled, scrunched, or moved in some mechanically stressful manner in order to generate an electric current with the quantity of piezoelectric material. Another embodiment of the energy-harvesting layer 9 is a quantity of pyroelectric material that is distributed throughout the flexible water-impermeable envelop 2. For the embodiment, the flexible water-impermeable envelop 2 would need to be thermally conductive so that heat passing through the water-impermeable envelop could be converted into an electric current by the quantity of pyroelectric material. Another embodiment of the energy-harvesting layer 9 is a quantity of triboelectric material that is distributed throughout the flexible water-impermeable envelop 2. For this embodiment, the flexible water-impermeable envelop 2 would need to be moved in some frictional manner in order to generate an electric current with the quantity of triboelectric material.
  • As can be seen in FIG. 3, the present invention may also be configured to gather energy from a conventional wireless charging pad. Thus, each of the at least one functional unit 1 may further comprise a wireless charging module 10, which preferably is an induction coil. The wireless charging module 10 is positioned within the flexible water-impermeable envelop 2 in order to properly secure the wireless charging module 10 to the present invention. The wireless charging module 10 is electrically connected to the flexible power-source layer 5 so that the wireless charging module 10 is able to recharge the flexible power-source layer 5.
  • As can be seen in FIG. 2, the present invention may also be configured to wirelessly communicate data with an external computing device. Thus, each of the at least one functional unit 1 may further comprise a wireless communication module 11, which can be, but is not limited to, a module facilitating a personal area network (e.g. Bluetooth), a module facilitating near field communication (NFC), or a module facilitating radio-frequency identification (RFID). The wireless communication module 11 is electronically integrated into the flexible PCB layer 6 so that the flexible PCB layer 6 is readily able to process incoming data from and/or outgoing data to the wireless communication module 11.
  • As can be seen in FIG. 4, the present invention may also be configured as a multi-sectioned foldable sheet. Thus, the at least one functional unit 1 needs to be a plurality of functional units 1, and the present invention needs to further comprise a plurality of conductive strips 12. The plurality of functional units 1 is arranged into a grid configuration so that the flexible water-impermeable envelop 2 of each of the plurality of functional units 1 can be foldably connected amongst each other. This allows the present invention to be configured into a multi-sectioned foldable sheet. Moreover, the flexible power-source layer 5 of each of the plurality of functional units 1 is electrically connected amongst each other by a corresponding strip from the plurality of conductive strips 12, which allows each of the plurality of functional units 1 to share power amongst each other.
  • One use of the present invention is designed to be used to manufacture smart clothing that has the appearance of traditional textiles and the functionality of a piece of wearable technology. As such, the base liner 3 and the sealant layer 4 form a water-impermeable membrane around the flexible power-source layer 5, the flexible PCB layer 6, the energy-harvesting layer 9, and/or the flexible accessory-interfacing layer 7. This configuration enables the present invention to be incorporated into a machine washable garment.
  • Another use of the present invention is as a thermally adaptive textile that is integrated into the base liner 3 and the sealant layer 4. The present invention would be able to change configuration in response to the user's body heat. This enables the present invention to expand when cooled and contract when heated. This functionality enables the present invention to moderate the user's body temperature.
  • The present invention can be implemented in a variety of other uses, which include, but is not limited to, the following. Another use of the present invention is as a foldable battery-solar pack, which is an energy storage or harvesting device applied on a flat sheet can be folded into multiple layers and reducing significant area. Another use of the present invention is as a weight-distributed flexible electronic device with a battery that can attach, slide, insert, zip, fasten, or snap onto a garment. Another use of the present invention is as a flexible battery circuitry mounted to a wearable band. Another use of the present invention is as a band integrated with a smart wearable device either connected physically or wirelessly. Another use of the present invention is as a clothing container, drawer, or closest with wireless charging and a flexible battery apparatus. Another use of the present invention is as a periphery garment of battery mount to textile that communicates to a smart phone or network. Another use of the present invention is as an apparatus that monitors a person's mental health, a person's physical health, a person's wound, a person's sleeping habits. Another use of the present invention is as a garment of drug delivery and monitoring. Another use of the present invention is as a flexible circuit with battery and communications for impact measurement on a head mounted item (e.g. hat, helmet, headband, sweatband). The present invention can also be designed to be dust resistant.
  • Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.

Claims (20)

What is claimed is:
1. A multilayered flexible electronics platform comprises:
at least one functional unit;
each of the at least one functional unit comprises a flexible water-impermeable envelop, a flexible power-source layer, a flexible printed circuit board (PCB) layer, and a flexible accessory-interfacing layer;
the flexible power-source layer, the flexible PCB layer, and the flexible accessory-interfacing layer being stackably positioned amongst each other;
the flexible power-source layer, the flexible PCB layer, and the flexible accessory-interfacing layer being positioned within the flexible water-impermeable envelop;
the flexible PCB layer being electronically connected to the flexible power-source layer and the flexible accessory-interfacing layer; and
the flexible power-source layer being electrically connected to the flexible PCB layer and the flexible accessory-interfacing layer.
2. The multilayered flexible electronics platform as claimed in claim 1 comprises:
each of the at least one functional unit further comprises an attachment mechanism; and
the attachment mechanism being externally mounted to the flexible water-impermeable envelop.
3. The multilayered flexible electronics platform as claimed in claim 1 comprises:
the flexible water-impermeable envelop comprises a base liner and a sealant layer;
the flexible power-source layer, the flexible PCB layer, and the flexible accessory-interfacing layer being positioned in between the base liner and the sealant layer; and
the base liner and the sealant layer being perimetrically connected to each other.
4. The multilayered flexible electronics platform as claimed in claim 1 comprises:
each of the at least one functional unit further comprises an energy-harvesting layer;
the energy-harvesting layer being stackably positioned amongst the flexible power-source layer, the flexible PCB layer, and the flexible accessory-interfacing layer;
the energy-harvesting layer being positioned within the flexible water-impermeable envelop; and
the energy-harvesting layer being electrically connected to the flexible power-source layer.
5. The multilayered flexible electronics platform as claimed in claim 4 comprises:
the energy-harvesting layer being a quantity of photoelectric material;
the flexible water-impermeable envelop being transparent; and
the quantity of photoelectric material being distributed throughout the flexible water-impermeable envelop.
6. The multilayered flexible electronics platform as claimed in claim 4 comprises:
the energy-harvesting layer being a quantity of piezoelectric material; and
the quantity of piezoelectric material being distributed throughout the flexible water-impermeable envelop.
7. The multilayered flexible electronics platform as claimed in claim 4 comprises:
the energy-harvesting layer being a quantity of pyroelectric material;
the flexible water-impermeable envelop being thermally conductive; and
the quantity of pyroelectric material being distributed throughout the flexible water-impermeable envelop.
8. The multilayered flexible electronics platform as claimed in claim 4 comprises:
the energy-harvesting layer being a quantity of triboelectric material; and
the quantity of triboelectric material being distributed throughout the flexible water-impermeable envelop.
9. The multilayered flexible electronics platform as claimed in claim 1 comprises:
a wireless charging module;
the wireless charging module being positioned within the flexible water-impermeable envelop; and
the wireless charging module being electrically connected to the flexible power-source layer.
10. The multilayered flexible electronics platform as claimed in claim 1 comprises:
a wireless communication module; and
the wireless communication module being electronically integrated into the flexible PCB layer.
11. The multilayered flexible electronics platform as claimed in claim 1 comprises:
a plurality of conductive strips;
the at least one functional unit being a plurality of functional units;
the plurality of functional units being arranged into a grid configuration;
the flexible water-impermeable envelop of each of the plurality of functional units being foldably connected amongst each other; and
the flexible power-source layer of each of the plurality of functional units being electrically connected amongst each other by a corresponding strip from the plurality of conductive strips.
12. A multilayered flexible electronics platform comprises:
at least one functional unit;
each of the at least one functional unit comprises a flexible water-impermeable envelop, a flexible power-source layer, a flexible printed circuit board (PCB) layer, a flexible accessory-interfacing layer, an attachment mechanism, and an energy-harvesting layer;
the flexible power-source layer, the flexible PCB layer, and the flexible accessory-interfacing layer being stackably positioned amongst each other;
the flexible power-source layer, the flexible PCB layer, and the flexible accessory-interfacing layer being positioned within the flexible water-impermeable envelop;
the flexible PCB layer being electronically connected to the flexible power-source layer and the flexible accessory-interfacing layer;
the flexible power-source layer being electrically connected to the flexible PCB layer and the flexible accessory-interfacing layer;
the attachment mechanism being externally mounted to the flexible water-impermeable envelop;
the energy-harvesting layer being stackably positioned amongst the flexible power-source layer, the flexible PCB layer, and the flexible accessory-interfacing layer;
the energy-harvesting layer being positioned within the flexible water-impermeable envelop; and
the energy-harvesting layer being electrically connected to the flexible power-source layer.
13. The multilayered flexible electronics platform as claimed in claim 12 comprises:
the flexible water-impermeable envelop comprises a base liner and a sealant layer;
the flexible power-source layer, the flexible PCB layer, and the flexible accessory-interfacing layer being positioned in between the base liner and the sealant layer; and
the base liner and the sealant layer being perimetrically connected to each other.
14. The multilayered flexible electronics platform as claimed in claim 12 comprises:
the energy-harvesting layer being a quantity of photoelectric material;
the flexible water-impermeable envelop being transparent; and
the quantity of photoelectric material being distributed throughout the flexible water-impermeable envelop.
15. The multilayered flexible electronics platform as claimed in claim 12 comprises:
the energy-harvesting layer being a quantity of piezoelectric material; and
the quantity of piezoelectric material being distributed throughout the flexible water-impermeable envelop.
16. The multilayered flexible electronics platform as claimed in claim 12 comprises:
the energy-harvesting layer being a quantity of pyroelectric material;
the flexible water-impermeable envelop being thermally conductive; and
the quantity of pyroelectric material being distributed throughout the flexible water-impermeable envelop.
17. The multilayered flexible electronics platform as claimed in claim 12 comprises:
the energy-harvesting layer being a quantity of triboelectric material; and
the quantity of triboelectric material being distributed throughout the flexible water-impermeable envelop.
18. The multilayered flexible electronics platform as claimed in claim 12 comprises:
a wireless charging module;
the wireless charging module being positioned within the flexible water-impermeable envelop; and
the wireless charging module being electrically connected to the flexible power-source layer.
19. The multilayered flexible electronics platform as claimed in claim 12 comprises:
a wireless communication module; and
the wireless communication module being electronically integrated into the flexible PCB layer.
20. The multilayered flexible electronics platform as claimed in claim 12 comprises:
a plurality of conductive strips;
the at least one functional unit being a plurality of functional units;
the plurality of functional units being arranged into a grid configuration;
the flexible water-impermeable envelop of each of the plurality of functional units being foldably connected amongst each other; and
the flexible power-source layer of each of the plurality of functional units being electrically connected amongst each other by a corresponding strip from the plurality of conductive strips.
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